Funded by the Horizon Europe research and innovation programme, FREE4LIB aims to enhance the recycling and remanufacturing of Lithium-Ion Batteries (LIBs) through a comprehensive circular ecosystem. One of the deliverables of this project is a study on metal reuse from electric batteries.
This study explores the potential of recycling aluminium from end-of-life electric vehicle (EV) battery packs and using it in 3D printing. It contributes to the broader project goal of creating sustainable solutions for battery recycling, aiming to recover valuable metals and reduce environmental impact. The deliverable shows how recovered materials can be transformed into high-quality products in advanced manufacturing, bridging the gap between waste management and industrial reuse.
Context and objective of the deliverable
EV batteries contain various aluminium alloys, which are usually discarded or underutilized at the end of battery life. Recovering and reprocessing these metals can reduce dependence on primary aluminium, which has a high environmental cost. The main objective of this study was to investigate whether recycled aluminium could be processed into powders suitable for additive manufacturing and to assess the quality of parts printed from these powders. A secondary goal was to explore initial possibilities for copper reuse in similar applications.
Key Findings
The deliverable highlights several important findings:
1) Powder production: Recycled aluminium was successfully melted, mixed, and atomized into fine powders with the right size and shape for 3D printing.
2) 3D printing quality: Printed parts were dense, with a consistent microstructure, and mechanical properties similar to those of commercial aluminium powders. The aluminium alloys produced through recycling and used in 3D printing are mainly Al-Si-Cu alloys. New alloy compositions are being investigated to improve performance and expand the range of potential applications.
3) Process robustness: The 3D printing process proved reliable across a range of parameters, making it flexible for industrial use.
4) Material performance: Hardness and tensile strength were within expected ranges, confirming that recycled aluminium can produce durable components.
These results demonstrate that recycling aluminium from EV batteries is not only feasible but also produces material suitable for advanced manufacturing applications, reducing waste and environmental impact.
Recommendations and next steps
• Optimize properties: Investigate small additions of other metals, such as copper, to improve strength.
• Expand material scope: Conduct further tests for copper powders to broaden the range of recycled materials usable in 3D printing.
• Scale-up production: Develop industrial-scale processes for atomization and powder production.
You can read the full deliverable here
